Operating Steel Wire; Dip In Lubrication; Injection Lubrication; Maintenance Of Operation System - ZONGSHEN ZS250GY-3 Service Manual

1 Structure and Working Principle of Operating Steel Wire
Operating steel wire mainly consists of steel wire,wire head and metal spring plastic hose.The steel wire
should be soft so that it doesn't break off easily and it can bear big pressure.It is normally made of several
thin wires,which ensure the intensity of steel wire and make it soft.The wire head is connected with steel
wire through the method of stannum jointing ,zins alloy die-casting and so on.The outside of metal spring
plastic hose is plastic and inside is a spring hose made of steel wire,which can bear any bending and
won't change the length when suffers axial pressure.There is a nylon bushing between the steel spring
plastic hose and steel wire,which avoids the direct friction of steel wire and spring hose.
2 Maintenance of Operating Steel Wire
In order to keep operating steel wire working well and prolong its sevice lifetme,termly cleaning and
lubricating is necessary.For the first time,you can do it after 1500km,and then every 3000km.Here are
two methods for lubrication:one is dip in,the other is injection.
wire head
steel wire
adhesive tape
metal hose
The cause,trouble description and repair method of operation system
Component
Description
handlebar
O p e r a t i n g
steel cable of
clutch
r e a r b r a k e
pedal
28
Section 7 Operating Steel Wire
oil kettle
Maintenance of Oper ation Sy stem
Trouble description
Cause
of component
Handlebar is Handlebar is
distorted. distorted.
Steel wire
Clutch handlebar
cannot flexibly is hard to be
pulled outside operated or cannot
the cable. be returned well.
Steel wire
breaks off.
The free stroke
is too small.
The free stroke
is too big.

(1)Dip In Lubrication

Operate as follows:
[1]Dip the whole steel wire in coal oil for 5-10min.
Pull the steel wire to clean out the deposit in hose.
[2]Dip the whole steel wire in the mixed oil which
has percentage of 1:1 of coal oil and luboil.Pull the
steel wire to make mixed oil flow into the hose.
[3]Remove operating steel wire and clean the
mixed oil outside.

(2)Injection Lubrication

Operate as follows:
[1]Enlace the end of metal spring plastic hose of
operating steel wire with transparent adhesive tape.
Make it as a pipe.As shown in figure:
[2]Raise the end with adhesive tape and pull out of
steel head.
[3]Dip luboil in the hose with oil kettle until there
is oil dripping from the lower steel wire.
Trouble description of motorcy
cle
Motorcycle runs towards one
side.
Clutch slides or cannot
disengage completely.
Clutch cannot disengage
completely.
Rear brake pedal cannot be
returned to the original place.
Rear brake loses control.
Repair method
Correct or replace
handlebar.
Clean,lubricate or replace
operating steel cable.
Replace operating steel
cable.
Readjust the free stroke.
Readjust the free stroke.